Method of making pepperoni flakes or pepperoni

ABSTRACT

The subject invention relates to a method of making pepperoni flakes or pepperoni. The applications for this invention are broad and would encompass any flavoring for a meat topping or ingredient product. Generally, the subject invention includes the use of fat raw materials rather than a lean/fat blend, the use of an emulsifier to reduce fat particle size and connective tissue, and a low moisture protein ratio of the end product. In addition, this method results in a rapid speed of the process. The product mixture is ground, cooked, and conveyed to a drum drier. The speed of the drum drier is determined by the desired moisture protein ratio, which is 1.6:1 or less for pepperoni.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The subject invention relates to a method of making pepperoniflakes or pepperoni.

[0003] 2. Description of the Prior Art

[0004] In preparing pepperoni products, it is desirous to obtain a finalproduct in a relatively short period of time that is still rich inflavor. In order to retain the flavor, it is necessary to retain some ofthe fat of the product, but this often leaves the final product feelinggreasy. Many processes known in the art include the use of acidulants orfermentation. These processes typically take about 10 to 14 days andresult in about 40% to 45% fat in the final product.

[0005] Several of prior art patents use acid solutions. In the patent toWistreich et al., U.S. Pat. No. 4,220,668, the sausage mixture isimmersed in a lactic acid and other edible organic acid solution forseveral hours, wherein the pH throughout the cross section of thesausage mixture is below 5.2 after treatment. U.S. Pat. No. 4,263,329 toOlson et al. also discusses the use of a lactic acid solution, whereinthe titratable acidity is 4% to 10% by weight. U.S. Pat. No. 4,279,935to Kentor discusses a rapid method of producing dry sausages butindicates that this “rapid” time is 5 to 20 days. This method usesbactericides, bacteriostats and at least one chemical acidulatingmaterial. In the patent to Alden et al., U.S. Pat. No. 5,639,495, aparticulate protein component and a lactic acid bacteria starter cultureare used in a fermentation process. In the patent to Holdren et al.,U.S. Pat. No. 5,736,186, a process for making dry sausage products isdiscussed wherein the product is dehydrated and the weight of moistureto the weight of protein ratio is no greater than 3.7:1. This processuses encapsulated acidulants with a melting point of at least 900 F,which lowers the pH of the product to less than 5.3.

[0006] In the patent to Fernandez et al., U.S. Pat. No. 5,639,504, a lowfat, low salt and low phosphate sausage is discussed. A vacuum packedencased product is subjected to hydrostatic pressure of 500 to 2000 barsto obtain a pressure treated product, which is unpacked prior to cookingthe encased product.

[0007] U.S. Pat. Nos. 5,688,549 and 5,698,255 to Roehrig et al. aredirected to the use of meat with a high fat content in the production ofhot dogs, sausages and hamburger patties. In U.S. Pat. No. 5,688,549,the fat content is reduced from approximately 60% to 10% by weight bypassing the heated comminuted meat into a centrifuge to subject the meatto gravitational forces sufficient to reduce its fat content. The liquidphase (fat) and the lean meat phase are then separated. In U.S. Pat. No.5,698,255, a high fat content meat is comminuted, heated and centrifugedto provide unformulated raw reduced fat meat having a fat content nogreater than 10% by weight.

[0008] U.S. Pat. No. 5,942,265 to Roberds et al. discusses a process ofextruding blended sausage into sheet form for fermentation and cooking.

[0009] Finally, U.S. Pat. No. 5,948,462 to Atsuta et al. discusses anemulsified composition of heat-denatured whey protein, edible oil andedible fat. This results in low fat sausage having a juicy feeling asusual sausage comprising animal fat such as hog fat and the like.

SUMMARY OF THE INVENTION

[0010] The subject invention relates to a method of making pepperoniflakes or pepperoni. In a preferred embodiment method for makingpepperoni, a product mixture is ground and heated, whereby a product iscreated. The product is then dried on a drum drier to obtain a moistureprotein ratio of 1.6:1 or less.

[0011] In a preferred embodiment method for making pepperoni flakes, aproduct mixture is ground and mixed, and then the product mixture isplaced in a vessel and heated to a temperature, whereby a product iscreated. The excess fat is drained from the product, and the product isdried on a drum drier where a moisture protein ratio of 1.6:1 or less isobtained. In a preferred embodiment, the product is then allowed to cooland is sized and packaged.

[0012] In another preferred embodiment method for making pepperoniflakes, a product mixture is ground and mixed, and then the productmixture is emulsified and stuffed into casing. Then, the product mixtureis cooked in a smokehouse, whereby a product is created. The product isallowed to cool, the casing is stripped off the product, and the productis ground. Then, the product is dried on a drum drier where a moistureprotein ratio of 1.6:1 or less is obtained. In a preferred embodiment,the product is then allowed to cool and is sized and packaged.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0013] The subject invention relates to a method of making pepperoniflakes or pepperoni. The applications for this invention are broad andwould encompass any flavoring for a meat topping or ingredient product.Generally, the subject invention includes the use of fat raw materialsrather than a lean/fat blend, the use of emulsification to reduce thefat particle size, and a moisture protein ratio of 1.6:1 or less in theend product. In addition, this method results in a rapid speed of theprocess.

[0014] The rapid speed of the process is significant because the processdoes not require the use of fermentation, cultures, or dry rooms. Also,this process lacks an acidification step to lower the pH of the productmixture. This process takes approximately one day as opposed to 10 to 14days in a dry room.

[0015] The use of fat raw materials is also significant because it helpsgive the product a softer bite and retain its flavor. Also, the cost offat raw materials is less expensive than the cost of a lean/fat blend ora lean raw material. Typically, fat raw materials contain approximately50% fat or more, while lean raw materials contain approximately 30% fator less. Because the fat is emulsified in the process, the pepperonidoes not feel greasy to the touch but still retains its flavor.Emulsification in this process occurs when the product mixture ischopped and/or run through an emulsion mill, which results in the fatparticles being finely dispersed within the product mixture. Therefore,the fat droplets cannot be seen readily by the human eye and when thepepperoni is dried on a drum, the fat droplets are retained in theproduct. This portion of the process resembles the processes used forhot dogs and bologna.

[0016] Finally, the moisture protein ratio of the end product istargeted for 1.6:1 or less for pepperoni. The moisture protein ratio ofpepperoni for this method is approximately 1:1.

[0017] The preferred embodiment method for making pepperoni flakes orpepperoni begins with using fat raw material such as belly trim, 42%lean pork, or pork jowls in the product mixture. Pork, beef or a mixtureof pork and beef could be used in the product mixture. Also, fat porkand/or fat beef with a 50% lean trim could be used. Using fat rawmaterial rather than a lean/fat blend results in a softer bite in thefinal product, and fat raw material is less expensive than a lean/fatblend. Typically, fat raw materials contain approximately 50% fat ormore, while lean raw materials contain approximately 30% fat or less.The preferred embodiment method uses raw material having a fat contentof approximately 45% to 60%, while other processes typically use a 30%to 33% lean/fat blend. Then, the product mixture is ground with a ¼ inchplate, which provides better mixing action for the product mixture.However, the product mixture could be ground either finer (using a 1/8to ¼ inch plate) or coarser (using a 3/8 to 1 inch plate) as long as theproduct mixture is ground to a size that mixes uniformly with the spicesadded to the formula. The product mixture is mixed, spices are added,and then the product mixture is mixed further for approximately 15minutes, or until the spices are evenly distributed within the productmixture. Spices that may be added include anise, garlic, red pepper,black pepper, white pepper, fennel, and paprika. In addition, sodiumnitrite is added as part of the cure to develop and enhance the redcolor of the product mixture. The product mixture is then transferred toa chopper/emulsifier where the product mixture is emulsified to a pastyconsistency. A double emulsifying plate having two 3.0 mm plates is usedto reduce the product mixture to a size of approximately 1.5 to 3.0 mm.In the preferred embodiment, a Griffith MINCE MASTER® Model 225-100 isused and the size of the opening in the plates is approximately 1.5 to3.0 mm. This step homogenizes the product mixture, reducing the size ofconnective tissue and fat particles within the product mixture.Emulsification in this process occurs when the product mixture ischopped and/or run through an emulsion mill, which results in the fatparticles being finely dispersed within the product mixture. This is acommon step in the production of sausage. Therefore, the fat dropletscannot be seen readily by the human eye and when the pepperoni is laterdried on a drum, the fat droplets are retained in the product mixture.Because the fat is emulsified in the process, the pepperoni does notfeel greasy to the touch but still retains its flavor. This portion ofthe process resembles the processes used for hot dogs and bologna.

[0018] Next, the product mixture is stuffed into a cook-in-bag casingand cooked for approximately 4 to 5 hours in a smokehouse having aninternal temperature of approximately 130 to 180° F., thereby cookingthe product mixture internally at approximately 152 to 158° F.Therefore, the product mixture is cooked well enough so that it is astable product. When the product mixture is first placed in thesmokehouse, the internal temperature of the product mixture isapproximately 40° F. and the internal temperature of the smokehouse isapproximately 130° F., and then the temperatures of the smokehouse andthe product mixture are raised to the temperatures stated. The use of aplastic casing prevents loss of moisture and/or fat when the productmixture is cooked in the smokehouse. Using a fiber casing risks losingmoisture, which is not desired at this point in the process. After theproduct mixture is cooked, it is referred to as a product. The productis then allowed to cool, the casing is stripped off, and the product isground with a ½ inch plate, but the product could be ground either finer(using a ⅛ to ½ inch plate) or coarser (using a ⅝ to 1 inch plate).

[0019] The product is then placed in a heated vessel with agitation.Agitation helps prevent the product from sticking to the vessel andensures that the product is cooked uniformly. The use of a vessel helpsprevent the loss of fat, and any source of heat may be used such assteam, gas, or electricity to heat the vessel. The preferred embodimentutilizes a steam-jacketed kettle, Groen Kettle Model TA200SP. Thetemperature is raised to approximately 180 to 210° F. to make a slurryof the product, and then the excess fat is then drained from theproduct. This helps the product roll over the drum drier more easily.The product is conveyed to a drum drier where the temperature isapproximately 260 to 300° F. and where the distance between the drums isapproximately 0.1 to 0.25 mm. The preferred embodiment uses Blow-KnoxDrum Drier Model VLC-4. When the product is dried on a drum, the drumdrier cooks the product and removes moisture from the product, which isnecessary to obtain a moisture protein ratio of 1.6:1 or less. Therequired moisture protein ratio for pepperoni is 1.6:1 or less, and thisprocess typically results in a moisture protein ratio of approximately1:1. The drum speed is determined by the desired moisture protein ratioof 1.6:1 or less or the water activity level of approximately 0.75 to0.85, and a revolution of the drums is approximately 45 to 90 seconds.The speed of the drum is adjusted periodically to obtain the desiredwater activity level of the product, which may be either too wet or toodry. The water activity level of approximately 0.75 to 0.85 ensures thatthe final product is a shelf stable product.

[0020] The dried product is then collected and allowed to cool. Then,the product is sized or cut to a proper size and packaged. The finalproduct is approximately 28 to 32% fat rather than 40 to 45% fat, whichis the typical percentage of pepperoni fat content. Therefore, theproduct is not as greasy because the fat is emulsified and not exposedwhen the product is dried. This method results in a very flavorfulproduct within about 1 to 1½ days without the use of cultures, dryrooms, acidification or fermentation, which typically takes about 10 to14 days.

[0021] Several of the steps discussed above in the preferred embodimentmethod are optional steps. A lean/fat blend could be used in the productmixture rather than a fat raw material, however, it is more expensiveand the additional fat helps give the final product a softer bite andmore flavor. Also, the use of ¼ inch and ½ inch plates during grindingof the product mixture and the product, respectively, are not the onlysize plates that can be used, and other suitable methods of grinding orsize reduction of the product mixture may be utilized. The productmixture can be ground finer or coarser, but the product mixture shouldbe ground to a size that blends well with the spices that are added. Theproduct mixture could be mixed for approximately 5 to 15 minutes whenthe spices are added, as long as the spices are mixed uniformlythroughout the product mixture. In addition, the use of thechopper/emulsifier is not necessary, but it homogenizes the productmixture and reduces the connective tissue and the fat particle sizewithin the product mixture. Therefore, if the chopper/emulsifier is notused, the grinding of the product mixture must be at a smaller size ofapproximately ⅛ to ¼ inch.

[0022] Also, placing the product mixture in casing and cooking theproduct mixture in a smokehouse are optional steps, but these stepsresult in a better final product. To carry out the process withoutcooking the product mixture in the smokehouse, the product mixture isfirst mixed in a chopper/emulsifier. This blending of the productmixture extracts proteins from the product mixture and makes it sticky,and clumping may occur if uncoated salt is added during this step in theprocess. Therefore, either encapsulated salt should be used or the saltshould be added later in the process, after the slurry is made, toprevent clumping of the product mixture. Then, the product mixture isplaced in a kettle where a slurry is made at approximately 120 to 130°F., and the product is dried on the drum drier as previously described.The advantage to cooking the product mixture in a smokehouse is that itmakes a more uniform product that performs better over the drum drier,and the cooking denatures the protein so the type of salt and when thesalt is added is a moot issue.

[0023] Finally, creating a slurry of the product and draining the excessfat from the product are also optional, but these steps help the productroll over the drum drier much more easily, resulting in a better finalproduct. In order for the subject method to work properly so as toresult in the desired final product, either the product mixture must becooked in a smokehouse or a slurry must be made, but both of these stepsare optional as long as the other step is employed. Without creating theslurry and draining the fat after the product is ground with the ½ inchplate, the product is fed over the drum drier, but the product tends tobe patchy over the drum drier, and the product tends to stick to thedrum. Therefore, creating the slurry first helps the product flow betterover the drum drier and results is a better final product.

[0024] The above specification, examples and data provide a completedescription of the manufacture and use of the composition of theinvention. Since many embodiments of the invention can be made withoutdeparting from the spirit and scope of the invention, the inventionresides in the claims hereinafter appended.

We claim:
 1. A method for making pepperoni, comprising the steps of: a.grinding and heating a product mixture whereby a product is created; andb. drying the product on a drum drier and obtaining a moisture proteinratio of 1.6:1 or less.
 2. The method for making pepperoni of claim 1,wherein the product mixture is made from fat raw material.
 3. The methodfor making pepperoni of claim 2, wherein said fat raw material is amaterial selected from the group consisting of fat pork material, fatbeef material, or a blend of fat pork material and fat beef material. 4.The method for making pepperoni of claim 1, wherein the product iscooked over the drum drier at approximately 260 to 300° F. at a drumspeed determined by a desired moisture protein ratio in step (b).
 5. Themethod for making pepperoni of claim 1, wherein the product has a wateractivity level of approximately 0.75 to 0.85 in step (b).
 6. A methodfor making pepperoni flakes, comprising the steps of: a. grinding andmixing a product mixture; b. placing the product mixture in a vessel andheating the product mixture to a temperature whereby a product iscreated; c. draining excess fat from the product; and d. drying theproduct on a drum drier and obtaining a moisture protein ratio of 1.6:1or less.
 7. The method for making pepperoni flakes of claim 6, whereinthe product mixture is made from fat raw material.
 8. The method formaking pepperoni flakes of claim 7, wherein said fat raw material is amaterial selected from the group consisting of fat pork material, fatbeef material, or a blend of fat pork material and fat beef material. 9.The method for making pepperoni flakes of claim 6, wherein said productmixture is ground to a size that will mix uniformly with spices, spicesare added to the product mixture, and the product mixture is mixed forapproximately 15 minutes in step (a).
 10. The method for makingpepperoni flakes of claim 6, wherein the product mixture is ground toapproximately ⅛ to ¼ inch in step (a).
 11. The method for makingpepperoni flakes of claim 6, wherein the product mixture is cooked atapproximately 180 to 210° F. in step (b).
 12. The method for makingpepperoni flakes of claim 6, wherein the product is cooked over the drumdrier at approximately 260 to 300° F. at a drum speed determined by adesired moisture protein ratio in step (d).
 13. The method for makingpepperoni flakes of claim 6, wherein the product has a water activitylevel of approximately 0.75 to 0.85 in step (d).
 14. The method formaking pepperoni flakes of claim 6, further comprising allowing theproduct to cool, sizing the product, and packaging the product.
 15. Amethod for making pepperoni flakes, comprising the steps of: a. grindingand mixing a product mixture; b. emulsifying the product mixture; c.stuffing the product mixture into casing; d. cooking the product mixturein a smokehouse whereby a product is created; e. cooling the product; f.stripping the casing off the product; g. grinding the product; and h.drying the product on a drum drier and obtaining a moisture proteinratio of 1.6:1 or less.
 16. The method for making pepperoni flakes ofclaim 15, wherein the product mixture is made from fat raw material. 17.The method for making pepperoni flakes of claim 16, wherein said fat rawmaterial is a material selected from the group consisting of fat porkmaterial, fat beef material, or a blend of fat pork material and fatbeef material.
 18. The method for making pepperoni flakes of claim 15,wherein the product is cooked over the drum drier at approximately 260to 300° F. at a drum speed determined by a desired moisture proteinratio in step (h).
 19. The method for making pepperoni flakes of claim15, wherein the product has a water activity level of approximately 0.75to 0.85 in step (h).
 20. The method for making pepperoni flakes of claim15, further comprising allowing the product to cool, sizing the product,and packaging the product.